Framing System and Method for Assembling the Same

ABSTRACT

A framing system has a plank member with ribs protruding therefrom and a frame member with a receptor pocket therein such that the rib of the plank member is resiliently engaged within the receptor pocket of the frame member to secure the plank member to the frame member. The plank member may also be laterally moved relative to the frame member such that the ribs slide within and engage the receptor pockets. The invention is also directed to a method for engaging the plank member with the frame member along with a method for fabricating the frame member.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.60/539,361, filed Jan. 27, 2004.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to frame construction, such as decks and docks,and, more particularly, to a fastener-free framing system by which plankmembers are secured to frame members through ribs which are engagedwithin receptor pockets.

2. Description of Related Art

Exterior decks are considered to be the most popular addition to homesthroughout the United States today. Decks are places where people canextend their living space beyond the walls of their home. Decks arebuilt out of a variety of materials and are fabricated in a variety ofdesigns.

Typically, decks and similar structures are constructed with horizontalplanking materials and are fastened to an underlying structural frame.The most popular planking and structural framing material is pressuretreated wood. Pressure treated wood contains harmful toxins; one of themis called Copper-Chromium Arsenic (CCA). It is designed to extend thelife of the product in exterior elements and protect it from weather andinsect infestation, such as termites. However, pressure treated woodplanking tends to warp, rot, splinter and require periodic maintenance.These problems are inherent only in wood and are accelerated in exteriorclimates.

The structural frame for the majority of the decks built in the UnitedStates is constructed out of pressure treated wood due to thefamiliarity and availability of the product. However, other alternativeplanking materials are plastic/wood composite, synthetic, extrudedplastics, extruded metals, cold-rolled metals, and extruded aluminum,etc.

Attaching the planking to the structural frame with fasteners, throughthe surface into the underlying structure, is the most commonly acceptedmethod in the industry. There are other methods that conceal thefastening system from the underside using special clips, brackets andthe like. However, this typically requires the same amount or additionalfasteners to adequately connect planking to the supporting substructure.

Attaching the planking to the structural frame through the top plankingsurface yields unsightly blemishes to the decking surface. Typically,planking members require two fasteners to be installed through itssurface into the underlying substructure (joists) to be adequatelyinstalled. More specifically, where a planking member crosses over theunderlying substructure, two fasteners must be installed.

Attaching the planking to the structural frame through the bottomplanking surface using specialty clips is a slow and tedious processrequiring more skilled labor and fasteners to adequately install. Thereare often space requirements below the structure and above the ground toadequately install subsurface fastening systems.

If nailed, these fasteners can work themselves out of the substructure,just above the surface, and cause injury. Special screws can reduce thechances of nail popping but are typically more expensive since they mustbe non-corrosive to avoid weathering and often require specialty toolsto fasten them. Fastening the planks to the substructure using screws isthe most advantageous method, however, it requires some skill toproperly place so that the fastening holes align somewhat consistentlywith the others.

As mentioned, wood structures have many disadvantages. They rot, warp,split, splinter, burn, require annual maintenance, burn, get eaten bytermites, are only produced in limited pre-cut lengths, and are notrecyclable just to name a few. In order to extend the life of woodstructures, special preservatives, like Copper-Chromium Arsenic (CCA)are applied to them. However these chemicals have been found to be toxicand the growing environmental impact concerns have led the EnvironmentalProtection Agency (EPA) to begin nationwide bans on these chemicalsstarting Jan. 1, 2004. There will be serious impacts on the industrylike lack of product supply, increased costs and product capabilities.

It is obvious that an alternative framing system that eliminatesfastening of the planking must be developed. If it is possible toproduce an alternative underlying framing structure that does notrequire chemicals treatment to make them effective, then that must bedeveloped as well. Currently, there are no solutions that integratepopular planking systems like composite and extruded decking materialswith the underlying substructure without the use of special fastenerslike screws, nails or clips, etc.

Therefore, an object of the present invention is to provide a plankmember that has a special shape integrated on the underside of theplank, which is used to attach itself to the underlying structurewithout fasteners.

SUMMARY OF THE INVENTION

One embodiment of the subject invention is directed to a framing systemcomprising a plank member having a front, generally fiat, surface and anopposing back surface with at least one rib protruding therefrom or atleast one receptor pocket extending therein. The framing system has aframe member of an underlying structure having at least one receptorpocket extending therein or at least one rib protruding therefrom,wherein the frame member rib or pocket is matable with the plank memberpocket or rib. The at least one rib has a profile with a first side anda second side which diverge from one another as they extend away fromthe member to which they are attached and then converge. The maximumheight of a rib occurs at the place of maximum divergence and thereceptor pocket has a minimum width less than that of the maximum heightof the rib such that the rib may be captured within the receptor pocket.

Another embodiment of the subject invention is directed to a plankmember comprising a front, generally flat, surface and an opposing backsurface with at least one rib protruding therefrom. The at least one ribhas a profile with a first side and a second side which diverge from oneanother as they extend away from the member to which they are attachedand then converge. The maximum height of a rib occurs at the place ofmaximum divergence such that the rib is adapted to be received within areceptor pocket having a minimum width less than that of the maximumheight of the rib.

Yet another embodiment of the subject invention is directed to a framemember of an underlying structure, wherein the frame member comprises atleast one receptor pocket extending therein, wherein the pocket isadapted to receive a rib. The receptor pocket has a minimum width lessthan that of the maximum height of the rib such that the rib may becaptured within the receptor pocket.

Yet another embodiment of the subject invention is directed to a methodof assembling a framing system having a plank member with a front,generally flat, surface and an opposing back surface with at least onerib protruding therefrom or at least one receptor pocket extendingtherein and having a frame member of an underlying structure with theother of at least one receptor pocket extending therein or at least onerib protruding therefrom, wherein the frame member rib or pocket ismatable with the plank member pocket or rib. The method comprises thesteps of:

-   -   a) aligning the at least one rib with the at least one receptor        pocket;    -   b) urging the at least one rib within the at least one receptor        pocket until the rib snaps into the pocket; and    -   c) wherein the at least one rib or the at least one receptor        pocket is resilient.

Still another embodiment of the subject invention is directed to amethod of making a frame member adapted to receive protruding ribs froma plank member comprising the steps of:

-   -   a) punching slots within a flat sheet; and    -   b) bending the sheet into a structural member having a top        surface and a bottom surface, wherein the slots extend within        the top surface to provide a receptor pocket adapted to receive        the protruding ribs from the plank member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a framing system in accordance with thesubject invention;

FIG. 2 is an enlargement of the encircled portion found in FIG. 1;

FIG. 3 is a section view indicating the manner in which the plank memberand frame member are engaged;

FIGS. 4A and 5A are section views similar to that of FIG. 3, butillustrating different embodiments of the plank member;

FIGS. 4B and 5B are section views identical to FIGS. 4A and 4B, exceptthe rib in each is in a compressed state;

FIGS. 6A and 6B are side views similar to that of FIG. 3, butillustrating how the frame member may deflect to accommodate the rib;

FIG. 7 is a section view of a framing system with the receptor pocketson the plank member and the ribs on the frame member;

FIG. 8 is a section view of the plank member with a separate piece ribattached thereto;

FIG. 9 is a section view of the framing system with overlapping plankmembers;

FIG. 10 is a side section view of a plank member and end view of a framemember;

FIGS. 11-16 are alternate embodiments of the plank member;

FIGS. 17A-17G illustrate sketches of different rib profiles;

FIG. 18 is a section view illustrating a dovetail arrangement for therib and receptor pocket;

FIG. 19 is a top view of a flat plate prior to being formed into a plankmember;

FIG. 20 is an end view of a finished plank member;

FIG. 21 is a side view of the framing system being utilized for a wall;and

FIG. 22 is an end view of a framing member with a rib embedded therein.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates the framing system 10 in accordance with the subjectinvention, while FIG. 2 illustrates an enlargement of the encircledportion of the framing system 10 in FIG. 1. The framing system 10 iscomprised of a plank member 15 having a front generally flat surface 17and an opposing back surface 19 with at least one rib 20 protrudingtherefrom. A frame member 25 of an underlying structure 27 has at leastone receptor pocket 30 extending therein. The rib 20 extending from theplank member 15 is matable with the receptor pocket 30 of the framemember 25.

FIG. 3 is a side view of a portion of the framing system illustratingthe manner by which the rib 20 of the plank member 15 engages thereceptor pocket 30 of the frame member 25. In particular, the rib 20 hasa profile with a first side 35 and a second side 37 which diverge fromone another as they extend away from the plank member 15 to which theyare attached. Thereafter, they converge and connect with one another.The maximum height H of the rib 20 occurs at the place of maximumdivergence. The receptor pocket 30 has a minimum width W less than thatof the maximum height H of the rib 20 such that the rib 20 may becaptured within the receptor 30. It should be noted that while the rib20 has a general shape of a teardrop, it will hereinafter be made clearthat this shape is not to be intended as a limitation to the subjectinvention.

As illustrated in FIG. 1, the plank member 15 and the frame member 25are secured to one another through the engagement of the ribs 20 withthe pocket receptors 30.

In one embodiment of the subject invention, the rib 20 is resilient suchthat the rib 20 deforms in order to enter the receptor pocket 30.Directing attention to FIG. 3, the height H of the rib 20 would diminishso that the rib 20 would be able to enter the receptor pocket 30. Thismay be achieved in one of at least two ways.

In particular, with attention directed to FIG. 4A, the rib 20 may have ahollow interior 40 such that a compressive force indicated by arrows 42will deform the walls 44 of the rib 20, as illustrated in FIG. 4B, suchthat the resultant height J is less than the width W of the openingwithin the receptor pocket 30. Because the rib 20 is resilient uponentry within the receptor pocket 30, the rib 20 will expand, therebylocking the plank member 15 within the frame member 25. The walls 44 ofthe rib 20 actually bend to provide the resiliency of the rib 20.

As illustrated in FIG. 5A, the rib 20 may also be made of a resilientmaterial which itself compresses. In particular, FIG. 5A illustrates therib 20 having a height H and subsequent to compressive forces 42, therib 20, which may be solid, resiliently compresses to a height J asshown in FIG. 5B, sufficient to fit within the receptor pocket 30.

It should be noted that the compressive forces 42 required to reduce thewidth of the rib 20 are those compressive forces generated by urging theplank member 15 against the receptor pocket 30 of the frame member 25.

In yet another embodiment of the subject invention illustrated in FIGS.6A and 6B, the receptor pocket 30 has receptor pocket walls 46, 48 whichinitially have a width K and are expanded by the rib 20 having a heightH such that the width K of the walls 46, 48 expands to accommodate theheight H of the rib 20, as illustrated in FIG. 6B. Under thesecircumstances, the rib 20 is relatively rigid and the materials of theframe member 25 must be resilient.

Typical materials that may be used for the rib 20 may be structuralmetal of any kind, wood, wood composites, cementitious composites,plastic composites, structural steel composites, fiberglass, and carboncomposites. It should be appreciated that this list is not exhaustiveand that any material suitable for the application described herein maybe suitable.

In each of these scenarios described in FIGS. 4A through 6B, at leastone rib 20 or the receptor pocket walls 46, 48 are rigid.

What has been discussed so far is a receptor pocket 30 within the framemember 25 and the rib 20 within the plank member 15. Directing attentionto FIG. 7, it is entirely possible for the plank member 15 to havereceptor pockets 50 while the frame member 25 has ribs 55 which engagethe receptor pockets 50 in the manner previously described.

Directing attention to FIG. 8, it is also possible for the rib 20 to bea separate piece 60 secured within the plank member 15 or, in thealternative, secured within the frame member 25, which is not shown butis an obvious variation of the arrangement illustrated in FIG. 8. Therib 20 may be secured to the plank member using any number of differentfastener techniques. As an example, the rib 20 may have a threaded shank62 which engages the plank member 15.

FIG. 9 illustrates a cross-section view of one embodiment of the framingsystem 10, whereby each plank member 15 has a recess 65 which is coveredby an overhang 70 in an adjacent plank member 15′. Such an arrangementpromotes retention of the plank member 15 within the frame member 25.

FIG. 10 illustrates a side view of the framing system 10, whereby therib 20 of the plank member 15 is aligned to be engaged with a pluralityof frame members 25. A complete framing system 10 may be comprised of aplurality of plank members 15 arranged side-by-side over a plurality ofspaced apart frame members 25.

In one embodiment illustrated in FIG. 11, the plank member 115 may havea tongue 117 on one side and a groove 119 on the other side which engagea mating groove 119′ in plank member 115′, and a mating tongue 117′associated with plank member 115″.

It should be appreciated that one focal point of the subject inventionis the interlocking ribs and receptor pockets. The plank member mayembrace a variety of different designs to satisfy the different needs towhich the framing system may be subjected.

FIG. 12 illustrates a plank member 215 having a generally ovalcross-section with ribs 220 similar to those previously discussedextending therefrom.

The material of the plank member discussed herein may be wood, compositewood, metal, plastic or a carbon fiber composite. As an example, if therib 220 of plank 220 is solid therethrough, then it is necessary for thematerial of the rib 220 to itself be resilient such that the rib 220resiliently fits within the receptor pocket 230 of the frame member 225.In the alternative, if the rib 220 has a hollow portion therein, then itis only necessary for the walls of the rib 220 to flex to fit within thereceptor pocket 230. Furthermore, as previously discussed, it is alsopossible for the receptor pocket walls to have resiliency themselves toaccept a rib 220.

FIG. 13 illustrates another variation of a plank member 315 having afront surface 317 and a back surface 319 with ribs 320 protrudingtherefrom. The variety of designs available for the plank member 315 areunlimited inasmuch as the back surface 319 has extending therefrom ribs320 that may interlock with receptor pockets (not shown) of a framemember.

FIGS. 14, 15 and 16 illustrate further variations of plank members 415,515, 615, respectively, having back surfaces for 419, 519, 619 with ribs420, 520, 620 extending therefrom. The designs illustrated in FIGS.14-16 are of particular interest because these designs may be fabricatedthrough extrusion processes using a variety of different materialsincluding structural steel, structural metal, and structural plastic orother structural materials capable of being extruded.

The ribs 20 so far discussed have been in the general shape of ateardrop. A number of other rib shapes may be used inasmuch as theseribs may be snapped into the receptor pocket 30 of the frame member 25.FIGS. 17A-17G illustrate a few such ribs 720 shapes. In each of theseshapes, the first side 722 divergence from the second side 724 and thenconverges. As a result, these ribs 720 may snap into an approximatelysized receptor pocket (not shown) located in the frame member. Asillustrated in FIGS. 17F and 17G, each rib 720 may also resemble a barb726.

Briefly returning to FIGS. 1 and 2, one method of attaching the plankmember 15 to the frame member 25 is to press the plank member 15 againstthe frame member 25 such that the ribs 20 resiliently deform to engagethe receptor pocket 30 or, in the alternative, a rib 20 engages theresilient walls 46, 48 of the receptor pocket 30 until the rib 20 snapsinto place within the receptor pocket 30. It should be appreciated that,to the extent the rib 20 conforms with the shape of the receptor pocket30, it is possible to slide the plank member 15 into the frame member 25such that the rib 20 engages the receptor pocket 30 without the need forresilient deformation. Under such circumstances, the plank member 15slides into the frame member 25 from the side. Since the rib 20 is nolonger required to resiliently fit with the receptor pocket 30, theshape of these two elements may change.

Directing attention to FIG. 18, a plank member 815 may have a rib 820 inthe shape of a dove-tail which engages the frame member 825 through areceptor pocket 830 in the shape of a matching dove-tail. It should beappreciated that, while the shape of the dove-tail has been presented,any number of different positive locking shapes may be utilized for thisarrangement.

The subject invention is also directed to a method of assembling aframing system 10 having a plank member 15 with the front generally flatsurface 17 and an opposing back surface 19 with at least one rib 20protruding therefrom or at least one receptor pocket 30 extendingtherein and having a frame member 25 of an underlying structure with theother of at least one receptor pocket 30 extending therein or at leastone protruding rib 20 extending therefrom. The frame member rib 20 orpocket 30 is matable with the plank member pocket 30 or rib 20. Themethod comprises the steps of aligning the ribs 20 with the receptorpockets 30. The ribs 20 are then urged within the receptor pockets 30until the ribs 20 snap into the pockets 30. For this to occur, the rib20 or the receptor pocket 30 must be resilient.

In an alternative embodiment, the method of assembling a framing system10 would comprise the steps of aligning the rib 20 with the receptorpocket 30 and sliding the rib 20 within the receptor pocket 30 untilproperly positioned. Under these circumstances, it is not necessary foreither the rib 20 or the receptor pocket 30 to be resilient.

So far illustrated is a frame member 25 having a generally C shape.Although other shapes may be utilized, this is a convenient shape thatwill typically be implemented for these structures. FIGS. 19 and 20illustrate the method by which the frame member 25 is manufactured froma flat sheet 900. In particular, openings 905 are punched within theflat sheet 900, wherein at each end of the opening 905 is a slightlyenlarged portion 910 which, in this instance, is designed to have thegeneral shape of a rib 15 illustrated in FIG. 1. Once the openings 905are punched, the flat sheet 900 is then bent into a structural memberhaving a top surface 915 and a bottom surface 920, wherein the openings905 extend within the top surface 915 to provide a receptor pocket 930adapted to receive the protruding ribs 20 from the plank member 15illustrated in FIG. 1.

While FIGS. 1 and 2 illustrate the use of the framing system 10 fordecking, the framing system 10 should not be limited to suchapplications and may be used in any application for which this design isappropriate. FIG. 21 illustrates the use of the framing system 10 as afence or a wall. The framing system in accordance with the subjectinvention may have a multitude of other applications including use as adock or an interior or exterior wall of a structure such as a building.

FIG. 22 illustrates a sketch whereby the rib 1020 is embedded within theframe member 1025. This may be achieved by embedding the rib 1020 duringan extrusion process used to form the frame member 1025.

While specific embodiments of the invention have been described indetail, it will be appreciated by those skilled in the art that variousmodifications and alternatives to those details could be developed inlight of the overall teachings of the disclosure. The presentlypreferred embodiments described herein are meant to be illustrative onlyand not limiting as to the scope of the invention which is to be giventhe full breadth of the appended claims and any and all equivalentsthereof.

1. A framing system comprising: a) a plank member having a front,generally flat, surface and an opposing back surface with at least onerib protruding therefrom or at least one receptor pocket extendingtherein; b) a frame member of an underlying structure having at leastone receptor pocket extending therein or at least one rib protrudingtherefrom, wherein the frame member rib or pocket is matable with theplank member pocket or rib; c) wherein the at least one rib has aprofile with a first side and a second side which diverge from oneanother as they extend away from the member to which they are attachedand then converge; d) wherein the maximum height of a rib occurs at theplace of maximum divergence; and e) wherein the receptor pocket has aminimum width less than that of the maximum height of the rib such thatthe rib may be captured within the receptor pocket.
 2. The framingsystem according to claim 1, wherein plank member and the frame memberare secured to one another through the engagement of the at least onerib with the at least one receptor pocket.
 3. The framing systemaccording to claim 3 wherein the at least one rib is resilient.
 4. Theframing system according to claim 4, wherein the at least one rib has ahollow interior and the rib bends for resiliency.
 5. The framing systemaccording to claim 4, wherein the material of the at least one rib iscapable of resilient bending.
 6. The framing system according to claim3, wherein the at least one rib is made of a resilient material thatcompresses for resiliency.
 7. The framing system according to claim 6,wherein the rib is solid and the material is compressible.
 8. Theframing system according to claim 2, wherein at least one receptorpocket has walls which are resilient.
 9. The framing system according toclaim 8, wherein the walls of the at least one receptor pocket arepushed apart to accommodate the rib.
 10. The framing system according toclaim 2, wherein one or both of the at least one rib and the at leastone pocket receptor are barbed.
 11. The framing system according toclaim 2, wherein the at least one rib and the walls of the at least onereceptor pocket are rigid.
 12. The framing system according to claim 1,wherein the at least one receptor pocket is within the frame member andwherein the at least one rib is within the plank member.
 13. The framingsystem according to claim 12, wherein the at least one rib is a separatepiece secured to the back surface of the plank member.
 14. The framingsystem according to claim 1, wherein the at least one receptor pocket isin the plank member and the at least one rib is in the frame member. 15.The framing system according to claim 1, wherein each plank memberinterlocks with an adjacent plank member.
 16. The framing systemaccording to claim 1, wherein each of the plank members are overlappingwith adjacent plank members.
 17. A plank member comprising: a) a front,generally flat, surface and an opposing back surface with the at leastone rib protruding therefrom; b) wherein the at least one rib has aprofile with a first side and a second side which diverge from oneanother as they extend away from the member to which they are attachedand then converge; d) wherein the maximum height of a rib occurs at theplace of maximum divergence such that the rib is adapted to be receivedwithin a receptor pocket having a minimum width less than that of themaximum height of the rib.
 18. The plank member according to claim 17,wherein the at least one rib is resilient.
 19. A frame member of anunderlying structure, wherein the frame member comprises: a) at leastone receptor pocket extending therein, wherein the pocket is adapted toreceive a rib; b) wherein the receptor pocket has a minimum width lessthan that of the maximum height of the rib such that the rib may becaptured within the receptor pocket.
 20. The frame member according toclaim 19, wherein the frame member is a C-shape structural member.
 21. Amethod of assembling a framing system having a plank member with afront, generally flat, surface and an opposing back surface with atleast one rib protruding therefrom or at least one receptor pocketextending therein and having a frame member of an underlying structurewith the other of at least one receptor pocket extending therein or atleast one rib protruding therefrom, wherein the frame member rib orpocket is matable with the plank member pocket or rib comprising thesteps of: a) aligning the at least one rib with the at least onereceptor pocket; b) urging the at least one rib within the at least onereceptor pocket until the rib snaps into the pocket; and c) wherein theat least one rib or the at least one receptor pocket is resilient.
 22. Amethod of making a frame member adapted to receive protruding ribs froma plank member comprising the steps of: a) punching slots within a flatsheet; and b) bending the sheet into a structural member having a topsurface and a bottom surface, wherein the slots extend within the topsurface to provide a receptor pocket adapted to receive the protrudingribs from the plank member.